Kia Carens. Manual — part 120

Tightening torque : 27~38 lb-ft(37~52 N·m, 3.8~5.3kg-m)

30. Reconnect crankshaft position sensor connector.

31. Reconnect ground strap with one bolt.

32. Reconnect vehicle speed sensor connector.

33. Reconnect back-up switch connector.

34. Reinstall air cleaner assembly.

35. Reconnect air temperature sensor connector.

36. Reconnect MAF sensor connector.

37. Reinsert data link connector.

38. Reinstall fresh air duct with two nut.

39. Reconnect position (first) then negarive (last) battery cables.

40. Add gear oil, refer to Oil inspection.

41. Test vehicle and check fluid levels.

Disassembly

1) Clean transaxle exterior throughly with stam cleaner or cleanin solvent before disassembly.
2) Clean removed parts (except sealed bearings) and all sealing surfaces with cleaning solvent, and dry with

compressed air.

3) Clean out all holse and passenges with compressed air and verify that there are no obstructions.

USING COMPRESSED AIR CAN CAUSE DIRT AND OTHER PARTICLES TO FLY OUT, CAUSING INJURY TO
EYES. WEAR PROTECTIVE EYE WEAR WHENEVER USING COMPRESSED AIR.

Locknut

1. Mount transaxle on ST(Ok130 990 007).

2. Lock primary shaft using SST(0K201 323 021).

3. Shift to 1st gear to lock rotation of secondart shaft.

4. Uncramp tabs of locknuts.

5. Remove locknuts from primary and secondary shafts.

Shift fork and shift rod assembly

1. Align ends of interlock sleeve and cotnrol leer (arrow). Turn shift rod counterclockwise.

2. While holdin 1st/2nd shift fork with one harnd and 3rd/4th shift fork with other, raise them both at same time and shift

both clutch bub sleeves.

3. Lift shift rod end and remove detent ball and, at same time, remove shift rod from clutch housing.

4. Separate shift rod and shift fork assemblies from both clutch nub sleeves.

Preinspection

5th gear thrust clearance

1. Measure 5th gear thrust clearance by suing dial indicator.

Clearance : 0.004~0.009 in (0.10~0.22 mm)
Maximum : 0.011 im (0.27 mm)

2. If clearance exceeds maximum, check contact surfaces of 5th gear and clutch hub. Repalce worn or damaged parts.

Assembly

5th/Reverse gear and housing parts

Assemble in order shown infigure, refer to Assembly note.

Primary shaft assembly and secondary shaft assembly

1. Install primary shaft assembly and secondary shaft assembly in to clutch housing as a unit.

Shift fork and shift rod assembly

1. Shift to 2nd gear and position shift fork and shift rod assembly as shown.

2. Insert spring seat and spring into reverse lever shaft, install detent ball, and place flat gasket scraper against it.

3. With edge of control end against scraper, push control end in direction of arrow so that detent ball hoes into shaft. This

will line up rod with shift rod coupling hole in clutch housing.

4. Set each clutch nub sleeve to neutral position, and tap shift rod from above so that detent ball goes into center groove

(of three grooves in control end).

5. Pull ball part of control end forward so that detent ball goes into recess in center groove.

Crank lever assembly and crank lever shaft

1. Install new O-ring to crank lever shaft.

2. Fit crank lever between change arm and control end, and insert crank lever shaft.

3. Align pin holes of crank lever shaft and clutch housing, and insert pin.

5th/reverse shift rod end and 5th/reverse shift rod

1. Install shift rod end (1) and shift rod (2), and tighten gate mounting bolt.

Tightening torque : 105~121 lb-in(11.8~13.7 N·m, 120~140kg-cm)

Reverse idle and reverse idle shaft

1. Install reverse idle gear and reverse idle shaft.

2. Attach magnet to clutch housing.

3. Align end of interlock sleeve with control lever(arrow), and face reverse idle shaft screw hole in direction shown in

figure.

Transaxle case assembly

1. Apply thin coat of sealant to contact surfaces of clutch housing and transaxle case, and tighten transaxle case

installation bolts to specified torque.

Tightening torque : 28~38 lb-ft (38~51 N·m, 3.8~5.3kg-m)